US20050040551A1 - Hardenable dental article and method of manufacturing the same - Google Patents
Hardenable dental article and method of manufacturing the same Download PDFInfo
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- US20050040551A1 US20050040551A1 US10/643,749 US64374903A US2005040551A1 US 20050040551 A1 US20050040551 A1 US 20050040551A1 US 64374903 A US64374903 A US 64374903A US 2005040551 A1 US2005040551 A1 US 2005040551A1
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- hardenable dental
- dental article
- mold cavity
- liner
- hardenable
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C5/00—Filling or capping teeth
- A61C5/70—Tooth crowns; Making thereof
- A61C5/77—Methods or devices for making crowns
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C13/00—Dental prostheses; Making same
- A61C13/08—Artificial teeth; Making same
- A61C13/081—Making teeth by casting or moulding
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C13/00—Dental prostheses; Making same
- A61C13/08—Artificial teeth; Making same
- A61C13/087—Artificial resin teeth
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C13/00—Dental prostheses; Making same
- A61C13/20—Methods or devices for soldering, casting, moulding or melting
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C5/00—Filling or capping teeth
- A61C5/30—Securing inlays, onlays or crowns
- A61C5/35—Pins; Mounting tools or dispensers therefor
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C13/00—Dental prostheses; Making same
- A61C13/0001—In-situ dentures; Trial or temporary dentures
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C13/00—Dental prostheses; Making same
- A61C13/08—Artificial teeth; Making same
- A61C13/09—Composite teeth, e.g. front and back section; Multilayer teeth
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C2202/00—Packaging for dental appliances
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61C—DENTISTRY; APPARATUS OR METHODS FOR ORAL OR DENTAL HYGIENE
- A61C2202/00—Packaging for dental appliances
- A61C2202/01—Packaging for light-curable material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/68—Release sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
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- Health & Medical Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Oral & Maxillofacial Surgery (AREA)
- Dentistry (AREA)
- Epidemiology (AREA)
- Veterinary Medicine (AREA)
- Animal Behavior & Ethology (AREA)
- Public Health (AREA)
- Manufacturing & Machinery (AREA)
- Engineering & Computer Science (AREA)
- Dental Preparations (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Dental Tools And Instruments Or Auxiliary Dental Instruments (AREA)
Abstract
Methods of manufacturing hardenable dental articles, packaged hardenable dental articles, and methods of packaging hardenable dental articles are disclosed. In various embodiments, the manufacturing may involve molding a hardenable dental material in a mold cavity that may be lined with a mold liner. The mold body may also form the package of the hardenable dental article formed within the mold cavity. In other embodiments, the hardenable dental articles may be provided in mold cavities located in sacrificial mold bodies that may be torn, stretched, softened, dissolved, etc. to release the hardenable dental articles in the mold cavities.
Description
- Restorative dentistry is an important market in today's dental industry. In particular, tooth repair with temporary and permanent crowns is a common procedure, typically requiring multiple dental appointments. Conventional technologies use liners, adhesives, pastes, two-part powder/liquid systems, preformed metal temporary crowns, and ceramic or porcelain/metal permanent crowns.
- Among the problems associated with the conventional technologies are the need for multiple visits to a dentist if a customized dental article is desired. Conversely, if customization is not desired, the dental article used may have a less than desirable fit and/or appearance, e.g., a metallic finish, larger gaps between proximal teeth, significant color variations from natural teeth, etc.
- Hardenable dental materials have been developed to address some of these issues. Examples of some of these materials are described in, e.g., International Publication No. WO 03/015720 (Karim et al.) and U.S. application Ser. No. 10/219,398 filed Aug. 15, 2002 (Karim et al.), both titled HARDENABLE SELF-SUPPORTING STRUCTURES AND METHODS. For the purposes of the present invention, “hardenable dental materials” are materials that are capable of being hardened to form dental articles such as crowns, etc.
- Although these materials may address the issues identified with respect to conventional technologies, they raise issues of their own with respect to the manufacturing, handling, and packaging of dental articles constructed of such materials. Many of these hardenable dental materials may exhibit significant levels of adhesion during manufacturing. As a result, shaping and handling of the hardenable dental materials into dental articles as a part of the manufacturing process may present challenges.
- Another potential issue raised with some hardenable dental materials is that the techniques used to form the hardenable dental materials into usable dental articles may contribute to or detract from the finished appearance of the dental articles. In other words, the hardenable dental material may exhibit an undesirable rough appearance due to less than desirable forming techniques and/or packaging.
- In addition, although the exact shape of dental articles manufactured of the hardenable materials before final hardening may be adjusted, significant shaping of the materials may not be possible or desirable depending on the properties of the hardenable dental material being used. For example, the dentist may prefer that the materials be provided in a shape that is close to the final desired shape of the dental article—subject to some minor shaping to provide a more customized fit and/or appearance. By providing the hardenable dental materials in a form that is close to the final form needed by the dentist, the time required for the dentist to complete any given dental procedure in which the dental article is used can be reduced. Such forming, however, may exacerbate the problems identified in the preceding paragraphs.
- The present invention provides methods of manufacturing hardenable dental articles, packaged hardenable dental articles, and methods of packaging hardenable dental articles. In various embodiments, the manufacturing may involve molding a hardenable dental material in a mold cavity that may be lined with a mold liner. The mold body may also form the package of the hardenable dental article formed within the mold cavity. In other embodiments, the hardenable dental articles may be provided in mold cavities located in sacrificial mold bodies that may be torn, stretched, softened, dissolved, etc. to release the hardenable dental articles in the mold cavities.
- The use of a mold liner during manufacturing of hardenable dental articles from hardenable dental materials may provide a number of potential advantages such as assisting with release of the hardenable dental article from the mold cavity; protecting the hardenable dental article from contamination, enhancing the finish of the hardenable dental article by providing a smooth finish on the article during the forming process (if the liner itself is smooth), and enhancing the finish of the dental article after hardening (if the smooth inside surface of the mold liner is retained in intimate contact with the outer surfaces of the hardenable dental article during hardening).
- If a mold liner is used in connection with the manufacturing of a hardenable dental article, it may be preferred that the mold liner be in intimate contact with the outer surfaces of the hardenable dental article after release of the hardenable dental article from the mold cavity. Alternatively, the hardenable dental article may release from the mold liner after or during its removal from the mold cavity.
- If the mold liner is retained on the outer surfaces of the hardenable dental article, various advantages may potentially be obtained. If, for example, the dental article is a crown and the hardenable dental material is a photocurable material, the mold liner may function as an actinic light barrier to retard the passage of actinic radiation that could otherwise prematurely harden the photocurable hardenable dental material. If the liner is malleable, the dentist may be able to customize or adjust the shape of the dental crown with the liner in place. Alternatively, the dentist may remove the liner before customizing.
- The liner may also function as a protective barrier for the outer surfaces of the hardenable dental article. If the liner is maintained in place on the outer surfaces of the hardenable dental article during hardening, it may protect the outer surfaces from, e.g., exposure to oxygen before and during the hardening process. If the liner is to be retained in place during hardening, the liner may be flexible to allow the dentist to customize or shape the hardenable dental article before hardening (if desired).
- By retaining the liner in place on the outer surfaces of the hardenable dental articles, the liner may also function as a portion of the packaging of the hardenable dental articles manufactured of hardenable dental materials in accordance with the present invention. For example, the liner (in intimate contact with the outer surfaces of the hardenable dental article) may function as a package cover while a package base is attached to contain the hardenable dental article therein (in a manner similar to a “blister pack”).
- Although mold cavities formed in reusable mold bodies made of conventional materials such as metals, etc. may be used in connection with manufacturing of hardenable dental articles of the present invention, the present invention may also include the use of mold cavities located in sacrificial mold bodies that include, e.g., lines of weakness formed therein, such that after molding or forming of the hardenable dental material into the shape of the selected hardenable dental article, the sacrificial mold body can be separated along the lines of weakness to remove the hardenable dental article from the mold cavity. Other sacrificial mold bodies may be manufactured of materials that can either be stretched or torn to remove the hardenable dental article in the absence of defined lines of weakness. Still other sacrificial mold bodies may be manufactured of materials that can be softened or dissolved by contact with a solvent (such as, e.g., water) that does not significantly adversely affect the hardenable dental article. For example, sacrificial mold bodies could be manufactured of water-soluble materials such that exposure to water (by, e.g., sprays, baths, etc.) softens or dissolves the sacrificial mold body such that the hardenable dental article can be removed—preferably without distorting the shape of the hardenable dental article. All of such mold bodies are described as “sacrificial” because they cannot be reused due to their destruction during the removal process.
- Removal of a hardenable dental article from a sacrificial mold body may be performed as part of the manufacturing process, with the shaped hardenable dental article being packaged for delivery to a customer after the hardenable dental article has been removed from the sacrificial mold cavity. Alternatively, the sacrificial mold body itself may form a part of the packaging of the hardenable dental article located therein, with removal of the hardenable dental article from the sacrificial mold cavity being performed by, e.g., the dentist or an assistant, at the point of use of the hardenable dental articles. Such sacrificial mold bodies may be used in connection with mold liners as well.
- As used herein, the term “dental article” includes, but is not limited to, dental restoratives and dental prostheses, including, e.g., temporary, intermediate, and permanent crowns and bridges, inlays, onlays, implants, dentures, and artificial teeth, etc., as well as orthodontic appliances (e.g., retainers, night guards, etc.), tooth facsimiles or splints, maxillofacial prostheses, and other customized structures.
- As used herein, a “hardenable dental article” may optionally be defined as a self-supporting structure of a hardenable dental material that is dimensionally stable and will maintain its shape (e.g., the preformed shape of a dental crown) without significant deformation at room temperature (i.e., about 20° C. to about 25° C.) for at least two weeks when free-standing (i.e., without any external support). Preferably, the hardenable dental articles of the present invention are dimensionally stable at room temperature for at least about one month, and, more preferably, for at least about six months. Also, it may be preferred that the hardenable dental articles of the present invention are dimensionally stable at temperatures above room temperature, more preferably up to about 40° C., even more preferably up to about 50° C., and even more preferably up to about 60° C. This definition applies in the absence of conditions or materials that would otherwise act to harden the hardenable dental article and in the absence of an external force other than gravity.
- In one aspect, the present invention provides a method of manufacturing a hardenable dental article by providing a mold cavity in a shape of a hardenable dental article, wherein the mold cavity has an opening; forcing a hardenable dental material into the mold cavity through the opening; providing a liner between the hardenable dental material and the mold cavity; and removing the hardenable dental material and the liner from the mold cavity, wherein the hardenable dental material has the shape of the hardenable dental article.
- In another aspect, the present invention provides a packaged hardenable dental article including a mass of hardenable dental material in the shape of a hardenable dental article, wherein the hardenable dental article has a base and outer surfaces extending from the base; a package cover conforming to and in intimate contact with the outer surfaces of the hardenable dental article, wherein the package cover includes a polymeric film plastically deformed by the mass of hardenable dental material; and a package base facing the base of the hardenable dental article; wherein the package cover and the package base are attached together about a periphery of the base of the hardenable dental article such that the hardenable dental article is contained within the package base and the package cover.
- In another aspect, the present invention provides a dental article that includes a sacrificial mold body with a sacrificial mold cavity in the shape of a hardenable dental article, wherein the sacrificial mold body includes at least one line of weakness formed therein, the at least one line of weakness defining at least two mold sections in the sacrificial mold body; and a mass of hardenable dental material located within the volume of the sacrificial mold cavity such that the hardenable dental material is in the shape of the hardenable dental article.
- In another aspect, the present invention provides a packaged hardenable dental article that includes a mass of hardenable dental material in the shape of a hardenable dental article, wherein the hardenable dental article has a base and outer surfaces extending from the base; a package cover conforming to and in intimate contact with the outer surfaces of the hardenable dental article, wherein the package cover includes a sacrificial mold body with a sacrificial mold cavity in the shape of the hardenable dental article, and wherein the sacrificial mold body includes at least one line of weakness formed therein, the at least one line of weakness defining at least two mold sections in the sacrificial mold body; and a package base facing the base of the hardenable dental article; wherein the package cover and the package base are attached together about a periphery of the base of the hardenable dental article such that the hardenable dental article is contained within the package base and the package cover.
- In another aspect, the present invention provides a dental article that includes a sacrificial mold body with a sacrificial mold cavity in a shape of a hardenable dental article, wherein the sacrificial mold cavity conforms to and is in intimate contact with outer surfaces of the hardenable dental article; and a mass of hardenable dental material located within the volume of the sacrificial mold cavity such that the hardenable dental material is in the shape of the hardenable dental article.
- In another aspect, the present invention provides a method of manufacturing a hardenable dental article by providing a sacrificial mold body with a sacrificial mold cavity in a shape of a hardenable dental article, wherein the sacrificial mold body includes a water soluble polymer; and forcing a hardenable dental material into the sacrificial mold cavity through the opening, wherein the hardenable dental material takes the shape of the hardenable dental article.
- In another aspect, the present invention provides a method of manufacturing a hardenable dental article by providing a sacrificial mold body with a sacrificial mold cavity in a shape of the hardenable dental article, wherein the sacrificial mold cavity has an opening, and wherein the sacrificial mold body includes at least one line of weakness formed therein, the at least one line of weakness defining at least two mold cavity sections in the sacrificial mold body; and forcing a hardenable dental material into the sacrificial mold cavity through the opening, wherein the hardenable dental material takes the shape of the hardenable dental article.
- These and other features and advantages of the present invention may be described in more detail in connection with various illustrative embodiments of the invention below.
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FIG. 1 is an exploded schematic diagram of one illustrative manufacturing process according to the present invention. -
FIG. 2 is a cross-sectional view of one illustrative hardenable dental article in a package according to the present invention. -
FIG. 3 is a schematic diagram of one illustrative variation in a manufacturing process according to the present invention. -
FIG. 4 is a schematic diagram of another illustrative variation in a manufacturing process according to the present invention. -
FIG. 5 is a schematic diagram of an alternative illustrative manufacturing process according to the present invention. -
FIG. 6 is a schematic diagram of the manufacturing process ofFIG. 5 , with the hardenable dental material located within the mold cavity. -
FIG. 7 is a schematic diagram of still another alternative illustrative manufacturing process according to the present invention. -
FIG. 8 is a plan view of the base of one illustrative hardenable dental article in a package in accordance with the present invention. -
FIG. 9 is a cross-sectional view of the hardenable dental article ofFIG. 8 taken alongline 9—9 inFIG. 8 . -
FIG. 10 is a perspective view of the outer surface of one illustrative sacrificial mold cavity/body used in connection with the present invention. -
FIG. 11 is a perspective view of the opposite side of the sacrificial mold ofFIG. 10 depicting the mold cavity formed therein. -
FIG. 12 is a side elevational view of an illustrative hardenable dental article on a base of the sacrificial mold body ofFIG. 10 after removal of the mold sections. -
FIG. 13 is a cross-sectional view of another illustrative sacrificial mold cavity according to the present invention. - In the following detailed description of illustrative embodiments, reference is made to the accompanying figures of the drawing, which form a part hereof, and in which are shown, by way of illustration, specific embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
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FIG. 1 is an exploded diagram illustrating one process of forming a hardenable dental article according to the present invention. The illustrated process includes amold cavity 10 formed in abody 12. Themold cavity 10 includes anopening 14 leading to the volume of the mold cavity itself, which is depicted in cross-section inFIG. 1 . In the depicted embodiment, themold cavity 10 is in the shape of a dental crown. It should, however, be understood that the hardenable dental articles of the present invention may include a wide variety of articles as discussed above. - The
mold body 12 may be formed in any suitable material or combination of materials, e.g., metals, polymeric materials, etc. that provide sufficient structural integrity to withstand the forming process as described herein. In some instances, themold body 12 may be formed in separable sections to facilitate removal of a hardenable dental article formed therein. Also, themold body 12 may be made of or coated with a material adapted to aid release of a hardenable dental article from the interior surfaces of themold cavity 10. For example, the interior surfaces of themold cavity 10 may be coated with, e.g., fluorinated polymers (e.g., PTFE, etc.), boron carbide, chrome, thin dense chrome, chromium nitride, electroless nickel infused with fluorinated polymers, modified tungsten disulfide (e.g., DICRONITE), etc. - In other variations, the
mold cavity 10 may be temperature controlled to assist in the molding process by, e.g., heating and/or cooling the temperature of the interior surfaces of themold cavity 10. In yet other variations, themold cavity 10 may be vented or evacuated during the molding process to enhance molding. Ultrasonic or other vibrational energy may also be used to enhance filling of themold cavity 10 and/or assist with release the article from themold cavity 10. - A
mold liner 20 is depicted inFIG. 1 as positioned in between a mass of hardenabledental material 30 and theopening 14 into themold cavity 10. Apin liner 40 is positioned between the mass of hardenabledental material 30 and acore pin 50. Thecore pin 50 is preferably used to force the mass of hardenabledental material 30 into themold cavity 10 through theopening 14 therein. As a result, thecore pin 50, a portion of thepin liner 40, the hardenabledental material 30, and a portion of themold liner 20 are all advanced in the direction ofarrow 52 as depicted inFIG. 1 . - The mass of hardenable
dental material 30 may be pre-formed into a shape suitable for molding into the desired finished dental article. The hardenabledental material 30 may be provided in the shape of, e.g., a circular cylinder, circular cone, rectangular prism, spherical pellet, etc. - Further, the shape of the
core pin 50 may be selected such that it enhances molding of the hardenabledental material 30 within themold cavity 10. In addition, it may be desirable if thecore pin 50 is shaped such that it seals or closes the mold cavity to, e.g., define the edge of the molded hardenable dental article and/or to prevent or reduce the chances of unwanted voids in the hardenabledental material 30 within themold cavity 10. The shape of thecore pin 50 may also be selected to impart a desired shape to the interior profile of the finished hardenable dental article. - The process illustrated in
FIG. 1 may be described as a compression molding process. It should, however, be understood that the hardenabledental material 30 may be formed into the shape of the hardenable dental article by any suitable process. Some suitable processes may include, but are not limited to, e.g., injection molding, forging, casting, vacuum forming, extrusion molding, thermoforming, transfer molding, blow molding, etc. - In the process, the
mold liner 20 may be stretched to conform to the shape of themold cavity 10. At the same time, the mass of hardenabledental material 30 is also molded to conform to the shape of themold cavity 10. The hardenabledental material 30, will, however, be slightly smaller than themold cavity 10 because themold liner 20 is interposed between the hardenabledental material 30 and the interior surfaces of themold cavity 10. - Stretching of the
mold liner 20 may reduce the chances of unwanted voids in the molded hardenable dental article (due to, e.g., wrinkling of the mold liner 20). Furthermore, stretching of themold liner 20 during the molding process may also enhance intimate contact between themold liner 20 and the outer surfaces of the molded hardenable dental article. - It should be understood that the
mold liner 20 is an optional component in the molding process. In other words, it may be possible to force the hardenabledental material 30 into themold cavity 10 and remove it therefrom after molding. Themold liner 20 may, however, provide some potential advantages as discussed herein with respect to removal of the hardenable dental material from themold cavity 10, packaging of the hardenable dental article, etc. - The
mold liner 20 may be constructed of a variety of different materials. For example, themold liner 20 may be manufactured of a deformable material that may be provided in sheet form over the opening 14 of themold cavity 10 and deformed under the molding conditions (e.g., temperature, pressure, etc.) used to form the hardenabledental material 30 into the desired shape. Examples of some suitable materials for themold liner 20 may include, but are not limited to, e.g., polypropylenes, polyethylenes, polyurethanes, vinyls, thermoplastic elastomers, elastomeric films (e.g., rubber, latex, etc.), fluorinated polymers (e.g., FEP, PFA, THV, ECTFE, etc.), plasticized PVC, elastic-plastic films (e.g., blends of KRATON and polypropylene), copolymers, water soluble polymers (e.g., selected from the group consisting of polyvinylpyrrolidones, polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, polyethylene oxides, polyacrylamides, polyacrylic acids, polysaccharides and synthetically modified polysaccharides (e.g., cellulose ether polymers), alginates (e.g., sodium alginate), polyethyl oxazolines, esters of polyethylene oxide, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, urethanes of polyethylene oxide and polypropylene oxide copolymers, etc.). Further, themold liner 20 may include one or more coatings (e.g., silicone, etc.) to enhance formability, release from the hardenable dental article, etc. - Although the
mold liner 20 is depicted as a unitary layer, it should be understood that it could be provided as a multilayer or other non-homogeneous structure to, e.g., provide different properties for the surface facing the hardenabledental material 30 as compared to the surface facing the interior surfaces of themold cavity 10. Examples of some different properties that may be achieved by a multilayer structure, coating, etc. may include, but are not limited to the tensile strength of themold liner 20, formability, durability, etc. - Also, it should be understood that the
mold liner 20 itself may be treated or processed to improve its molding properties during forming of the hardenabledental material 30 in themold cavity 10. For example, it may be desirable to preheat or heat themold liner 20 during or just before the molding process begins to enhance its formability. - In the depicted process, the
pin liner 40 is also optional, i.e., it may or may not be provided. One potential advantage of providing apin liner 40 between thecore pin 50 and the hardenabledental material 30 is that adhesion between thecore pin 50 and the hardenabledental material 30 may be prevented. Another potential advantage is that thepin liner 40 may be incorporated into a package for the hardenabledental material 30 after it has been molded into the shape of themold cavity 10. - If the
pin liner 40 is not present, it may be desirable that thecore pin 50 have an outer surface (i.e., the surface that contacts the hardenable dental material 30) that exhibits limited or no adhesion to the hardenabledental material 30 during the molding process. For example, thecore pin 50 may be coated with, e.g., fluorinated polymers (e.g., PTFE, etc.), boron carbide, chrome, thin dense chrome, chromium nitride, electroless nickel infused with fluorinated polymers, modified tungsten disulfide (e.g., DICRONITE), etc. - The
core pin 50 may be temperature controlled to assist in the molding process by, e.g., heating and/or cooling the temperature of thecore pin 50. In other variations, thecore pin 50 may be vented or include vacuum orifices to assist in forming the hardenabledental material 30. In some instances, ultrasonic or other vibrational energy may be supplied to thecore pin 50 during the forming process. - In other instances, the
core pin 50 may be provided as a separate piece part attached to a driver such that thecore pin 50 can remain attached to the molded hardenabledental material 30 after it is removed from themold cavity 10 to assist in handling and/or packaging of the hardenable dental article. - The
pin liner 40 may be constructed of a variety of different materials. For example, thepin liner 40 may be manufactured of a stretchable material that may be provided in sheet form between thecore pin 50 and the hardenabledental material 30 and deformed under the molding conditions (e.g., temperature, pressure, etc.) used to form the hardenabledental material 30 into the shape of themold cavity 10. Examples of some suitable materials for thepin liner 40 may include, but are not limited to the same materials described herein for themold liner 20. - Stretching of the
pin liner 40 may reduce the chances of unwanted voids in the molded hardenable dental article (due to, e.g., wrinkling of the pin liner 40). Furthermore, stretching of thepin liner 40 during the molding process may also enhance intimate contact between thepin liner 40 and the molded hardenable dental article. - Although the
pin liner 40 is depicted as a unitary layer, it should be understood that it could be provided as a multilayer or other non-homogeneous structure to, e.g., provide different properties for the surface facing the hardenabledental material 30 as compared to the surface facing the outer surfaces of thecore pin 50. Examples of some different properties that may be achieved by a multilayer structure, coating, etc. may include, but are not limited to the tensile strength of thepin liner 40, formability, durability, control over surface energy, control over release properties, etc. - Also, it should be understood that the
pin liner 40 itself may be treated or processed to improve its molding properties during forming of the hardenabledental material 30. For example, it may be desirable to preheat or heat thepin liner 40 during or just before the molding process begins to, e.g., enhance its formability. - After removing the hardenable
dental material 30 andmold liner 20 from themold cavity 10, at least a portion of theliner 20 may be retained in intimate contact with the outer surfaces of the hardenable dental article formed of the hardenabledental material 30. One example of such a construction is depicted inFIG. 2 . - In
FIG. 2 , one embodiment of a packaged, shaped hardenabledental article 160 manufactured in accordance with the present invention is depicted in a cross-sectional view. The hardenabledental article 160 includesouter surfaces 162 that are in intimate contact withpackage cover 120. The hardenabledental article 160 also includes abase 164 and apackage base 140 located over thebase 164. - The
package cover 120 may include aflange 124 extending away from the hardenabledental article 160 proximate thebase 164. Theflange 124 may provide a convenient location at which thepackage base 140 may be attached to theflange 124 such that the hardenabledental article 160 is sealed within thepackage cover 120 and thepackage base 140. Theseal 128 between thepackage cover 120 and thepackage base 140 may be accomplished by any suitable technique or combination of techniques, e.g., heat sealing, adhesives, cold sealing, chemical welding, ultrasonically, etc. Theseal 128 may be a peelable seal, i.e., separation of thepackage cover 120 and thepackage base 140 be accomplished without significant deformation of the hardenabledental article 160 located therein. - The area of the flange 124 (or any other location on
package cover 120 or package base 140) may also provide a convenient location for indicia that may be useful to identify the hardenable dental article, the hardenable dental material, a date by which the hardenable dental article should be used, etc. - With reference to the process illustrated in
FIG. 1 , thepackage cover 120 may be formed from themold liner 20 and thepackage base 140 may be formed from thepin liner 40. If the hardenabledental article 160 is to be a hollowed out dental crown, then a void 154 may be formed in thebase 164 of the hardenabledental article 160 as seen inFIG. 2 . - Although the
package cover 120 and thepackage base 140 are each depicted as unitary layers, it should be understood that one or both could be provided as a multilayer or other non-homogeneous structure to, e.g., provide different properties for the surface facing the hardenabledental article 160 as compared to the surface facing away from the hardenable dental article, to provide vapor barrier properties, to provide moisture barrier properties, to provide sealing layers (e.g., heat sealable thermoplastic layers, adhesive layers, etc.). - In a variation from the process as shown in
FIG. 1 , thepackage base 140 may not be deformed as part of the process of forming the hardenable dental material. Rather, thepackage base 140 may be provided as a pre-formed piece having the shape seen inFIG. 2 that is inserted into the mass of hardenable dental material (30 inFIG. 1 ). In such an embodiment, thepackage base 140 may include a void 154 as depicted inFIG. 2 that may receive a core pin shaped driver (see, e.g.,core pin driver 50 inFIG. 1 ) during the manufacturing process. Alternatively, thepackage base 140 may be formed with a solid mass of material in the volume of the void 154, with that solid mass of material having sufficient strength to deform the hardenable dental material during manufacturing of the hardenabledental article 160. - If the hardenable
dental article 160 is manufactured of, e.g., a photocurable material, thepackage cover 120 and/orpackage base 140 may function as an actinic light barrier to provide protection from actinic radiation that may otherwise prematurely harden the hardenable dental material forming the hardenabledental article 160. For example, thepackage cover 120 and/or thepackage base 140 may transmit less than 1% of actinic radiation incident thereon. Methods and materials of providing such light barrier properties (e.g., by pigments, etc.) are known to those skilled in the art. Examples may be described in U.S. Pat. No. 5,538,129 (Chester et al.); U.S. Pat. No. 5,552,177 (Jacobs et al.); U.S. Pat. No. 5,636,736 (Jacobs et al.); and U.S. Pat. No. 5,785,178 (Kvitrud et al.), etc. - The
package cover 120 and/orpackage base 140 materials and/or construction may be selected to provide a desired level of oxygen permeability to control exposure of the hardenabledental article 160 located therein to oxygen during, e.g., storage. -
FIG. 3 illustrates another variation in the manufacturing process in which amold liner 220 is located over the opening 214 of amold cavity 210. The depictedmold liner 220 is partially deformed before the hardenabledental material 230 is introduced into themold cavity 210. The preforming may be accomplished by forcing theliner 220 into themold cavity 210. Alternatively, preforming of themold liner 220 may occur outside of themold cavity 210. Preforming of themold liner 220 in this manner may be accomplished with a tool (not shown) or by any other suitable technique such as fluid pressure, vacuum within themold cavity 210, etc. It may be helpful if themold liner 220 is heated or otherwise processed to improve its formability. -
FIG. 4 also illustrates another variation in the manufacturing process in which themold liner 320 is deformed such that it replicates the shape of themold cavity 310 before hardenabledental material 330 is introduced into themold cavity 310. As above, preforming of themold liner 320 in this manner may be accomplished with a tool (not shown) or by any other suitable technique such as, e.g., fluid pressure, vacuum within themold cavity 310, etc. It may be helpful if themold liner 320 is heated or otherwise processed to improve its formability. -
FIGS. 5 & 6 depict another manufacturing process in which the hardenabledental material 430 is located within apocket 421 formed inmold liner 420 before themold liner 420 and hardenabledental material 430 are introduced into themold cavity 410. As seen inFIG. 5 , the process includes anoptional pin liner 440 located between the hardenabledental material 430 and thecore pin 450.FIG. 6 depicts the hardenable dental material formed into the shape of a hardenabledental article 460 withincavity 410, including a void 454 formed by thecore pin 450. - The
pocket 421 inmold liner 420 may be formed under conditions of pressure, temperature, etc. using the hardenabledental material 430 itself. For example, upstream of the portion of the manufacturing process depicted inFIG. 5 , the hardenabledental material 430 may be forced against themold liner 420 under conditions of temperature, pressure, etc. such that the portion of themold liner 420 forming thepocket 421 is permanently or plastically deformed. Alternatively, themold liner 420 itself may be deformed by, e.g., vacuum forming, blow molding, cold forming/embossing, thermoforming, injection molding, compression molding, etc., such that thepocket 421 is formed before the hardenabledental material 430 is placed therein. - The
mold liner 420 andpin liner 440 may be retained in intimate contact with the hardenabledental article 460 and attached together to form a package containing the hardenabledental article 460 after removal from themold cavity 410 if so desired (and as described with respect to other embodiments elsewhere herein). -
FIG. 7 depicts still another alternative manufacturing process according to the present invention in which the hardenabledental material 530 is located within a volume defined by amold liner 520 and apin liner 540 before the hardenabledental material 530 and themold liner 520 are introduced into themold cavity 510. In this embodiment, the mass of hardenabledental material 530 may also be sealed within themold liner 520 andpin liner 540 before forming. For example, themold liner 520 andpin liner 540 may be adhered together, heat sealed, cold sealed, chemically welded, ultrasonically welded, etc. to enclose the hardenable dental material. - As discussed with respect to
FIGS. 5 & 6 , the hardenabledental material 530 may be located within apocket 521 formed in themold liner 520. Alternatively, however, thepin liner 540 may be used to form a pocket in addition to or in place of thepocket 521 formed in the mold liner. -
FIG. 8 is a plan view of thebase 664 of a hardenabledental article 660 located within aliner 620 andFIG. 9 is a cross-sectional view of the hardenabledental article 660 andliner 620 taken along line 9-9 inFIG. 8 . Theliner 620 is preferably in intimate contact with theouter surfaces 662 of the hardenabledental article 660. The hardenabledental article 660 andliner 620 depicted inFIGS. 8 & 9 may be manufactured using the methods described above. - The
liner 620 includes aflange portion 628 extending away from the hardenabledental article 660. Theliner 620 may be a stretchable film or other structure such that deforming (e.g., stretching, tearing, etc.) theliner 620 causes it to release from theouter surfaces 662 of the hardenabledental article 660 with little or no deformation of the shape of the hardenabledental article 660. To improve the release characteristics, it may be desirable to provide one ormore slits 626 in theflange portion 628 of theliner 620 and grasp theflange portions 628 to stretch theliner 620 in the directions ofarrows 627 and/or tear it along theslits 626. If theliner 620 is made of a water soluble polymer, removal of the hardenabledental article 660 may be facilitated by contacting theliner 620 with water (by, e.g., spraying, immersion in a water bath, etc.). -
FIGS. 10 & 11 are perspective views, respectively, of the outer and base surfaces of one exemplary embodiment of a sacrificial mold cavity that may be used to manufacture and, potentially, package a hardenable dental article according to the present invention. Thesacrificial mold cavity 710 is formed in asacrificial mold body 712 that may include one or more lines ofweakness 716 formed therein, wherein the lines of weakness definesections 717 in thesacrificial mold body 712. - The interior surfaces 711 of the sacrificial mold cavity 710 (see
FIG. 11 ) are in the shape of the desired hardenable dental article such that when hardenable dental material is forced into thesacrificial mold cavity 710, it takes the shape of the desired hardenable dental article in thesacrificial mold cavity 710 itself. - The lines of
weakness 716 may define lines along which thesacrificial mold body 712 may separate when tension is applied across the line ofweakness 716 or when a shearing force is generated on opposite sides of the line ofweakness 716. The lines ofweakness 716 may take a variety of forms, e.g., thinned lines in which the wall thickness of themold body 712 is reduced relative to the surrounding wall thickness, score lines formed after themold body 712 is manufactured, etc. In yet another variation, each line ofweakness 716 may be defined by a filament molded in thebody 712 such that the body preferentially separates along the filament. Other variations of providing a means of separation for a sacrificial mold cavity may be envisioned by those skilled in the art. - Lines of weakness may be provided in any desired orientation on the sacrificial mold body 712 (i.e., the depicted lines of
weakness 716 are not to be construed as limiting the orientation of lines of weakness used in connection with the invention). For example, for asacrificial mold cavity 710 forming a dental crown, lines of weakness that extend around thesacrificial mold body 712 in helical spirals from the portion of themold cavity 712 forming the margin to the incisal/occlusal surfaces of the dental crown may alternatively be provided. Other variations in the orientation or paths of lines of weakness used in connection with sacrificial mold cavities of the present invention may also be provided. - The
mold body 712 may also include a flange ortab 718 associated with one or more of themold sections 717. Thetabs 718 may be used to facilitate handling of themold body 712, to provide a location on which a package base may be attached to seal thesacrificial mold cavity 710 after locating the hardenable dental material therein, and/or to provide a location at which themold body 712 may be grasped to apply the force required to separate the one or more lines ofweakness 716 in themold body 712. - The flanges 718 (or any other location on the mold body 712) may also provide a convenient location for indicia that may be useful to identify the hardenable dental article, the hardenable dental material, a date by which the hardenable dental article should be used, etc.
- Separation of the
sacrificial mold body 712 along the one or more lines ofweakness 716 may be facilitated by a variety of optional features. For example,notches 715 may be provided at the ends of the lines ofweakness 716. Thenotches 715 may act as stress concentrators to initiate separation along the lines ofweakness 716. In the depicted embodiment, thenotches 715 are formed in betweenadjacent tabs 718, with thenotches 715 transitioning into thinned lines ofweakness 716. - Another optional feature depicted in connection with the
sacrificial mold body 712 is a base line of weakness that extends about the periphery of themold body 712 proximate, e.g., the incisal/occlusal surfaces formed by themold cavity 710. As eachsection 717 is separated from its adjacent section or sections 717 (in a process similar to, e.g., peeling petals from flower), the sections may be separated completely from themold body 712 along base line of weakness. After all of thesections 717 are removed, the base line of weakness may preferably define a base 772 that may remain attached to the hardenabledental article 760 as seen inFIG. 12 . A post orstud 774 attached to the base 772 as depicted may facilitate handling of the hardenabledental article 760. - The
mold body 712 may be manufactured of any suitable material or materials that may be provided in the desired shape and that will function to form or shape the hardenable dental material used to form the hardenabledental article 760. Examples of suitable materials for themold body 712 may include, but are not limited to, thermoplastic polymers, thermoplastic elastomers, polyethylenes, polypropylenes, polystyrenes, polyesters (e.g., poly(ethylene terephthalate)), etc. - A number of approaches may be employed to facilitate release of the
interior surface 711 of thesacrificial mold cavity 710 from the hardenable dental material used to form the hardenabledental article 760. For example, additives may be provided in the material used to form the mold body. Examples of some suitable additives may include, but are not limited to, fluoropolymers, graphite, fatty acids, low molecular weight polyethylene, silicone, hydrocarbon waxes, metallic stearates, etc. In another example, theinterior surfaces 711 of thesacrificial mold cavity 710 may include a coating formed thereon to enhance release from the hardenable dental material, e.g., silicone, fluorinated polymers, etc. - In still another approach, a mold liner (as described above with respect to
FIGS. 1 and 3 -7) may be used in connection with thesacrificial mold cavity 710. If a mold liner is used, it may be retained in intimate contact with the outer surfaces of the hardenable dental article after removal of themold body 712. - Furthermore, if no mold liner is used in connection with
sacrificial mold cavity 710, it is preferred that the lines ofweakness 716 do not include any voids, perforations, or other structures that could fill with the hardenable dental material during the molding process because such features would change the shape of the hardenabledental article 760 thus formed. For example, it may be preferred that, on theinterior surfaces 711 of thesacrificial mold cavity 710, the lines ofweakness 716 be indistinguishable from the remainder of theinterior surfaces 711 of thesacrificial mold cavity 710. If, however, a mold liner is used, then the lines ofweakness 716 may include voids (e.g., lines of perforations formed in the mold body 712) because such perforations could be sealed by the mold liner. Furthermore, such perforations may act to vent thesacrificial mold cavity 710. - Although the exemplary embodiment of a sacrificial mold cavity of
FIGS. 10-12 includes lines of weakness formed therein, other sacrificial mold cavities used in connection with hardenable dental articles of the present invention may not include lines of weakness to assist in removal of the hardenable dental articles. For example, another sacrificial mold cavity may be made of, e.g., an elastomeric material (e.g., rubber, thermoplastic elastomers, etc.) or a material exhibiting a low tear strength. - The internal surfaces of a sacrificial mold cavity may have the shape of the hardenable dental article while the external surfaces of the sacrificial mold body in which the mold cavity is located may conform to the shape of the hardenable dental article located within the cavity. One example of such a sacrificial mold body and cavity is depicted in, e.g.,
FIG. 2 in the form of thepackage cover 120. - Alternatively, the exterior shape of a sacrificial mold cavity may not conform to the shape of the hardenable dental article located within the mold cavity. For example, the exterior shape of the sacrificial mold cavity may be a generic shape such as, for example, a block, cylinder, etc.
- If any sacrificial mold body used in connection with the present invention does not, itself, possess sufficient strength to mold or form the hardenable dental material, then the sacrificial mold body (and the mold cavity it contains) may be supported by a support structure during the molding process. One example of a suitable support structure may be, e.g., the
mold cavity 10 depicted in connection withFIG. 1 and described as one example of a structure used to form thepackage cover 120 ofFIG. 2 . - Typically, the support structure will preferably conform to the exterior shape of the sacrificial mold body in which the sacrificial mold cavity is located. As a result, if the exterior shape of the sacrificial mold body (such as package cover/
mold body 120 ofFIG. 2 ) conforms to the shape of the hardenable dental article, then the support structure used to support the mold body will include interior surfaces that also conform to the exterior shape of the sacrificial mold body. If the exterior shape of the sacrificial mold body is generic, i.e., in the shape of a cylinder, block, etc., then the support structure used to support the mold body will typically include interior surfaces that conform to the generic shape of the sacrificial mold body. - One illustrative example of a sacrificial mold cavity having a generic outer shape and an inner cavity in the shape of a desired hardenable dental article is depicted in
FIG. 13 , wheremold body 812 defines a mold cavity withinner surfaces 810. A hardenabledental article 860 is formed within the mold cavity defined byinner surfaces 810. The hardenabledental article 860 may include aninner cavity 854. - The
mold body 812 may be formed of, e.g., elastomeric materials and/or materials exhibiting low tear strength to facilitate removal of the hardenabledental article 860 as discussed above. Alternatively, the mold body may be formed of soluble polymers (e.g., water soluble polymers selected from the group consisting of polyvinylpyrrolidones, polyvinylpyrrolidone/vinyl acetate copolymers, polyvinyl alcohols, polyethylene oxides, polyacrylamides, polyacrylic acids, polysaccharides and synthetically modified polysaccharides (e.g., cellulose ether polymers), alginates (e.g., sodium alginate), polyethyl oxazolines, esters of polyethylene oxide, esters of polyethylene oxide and polypropylene oxide copolymers, urethanes of polyethylene oxide, urethanes of polyethylene oxide and polypropylene oxide copolymers, etc.). The hardenabledental article 860 could be removed from thesacrificial mold body 812 at some point after the forming operation either by softening and/or dissolving thesoluble mold body 812 through contact with an appropriate solvent (e.g., a water bath or spray for water soluble polymers). - All references and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure. Illustrative embodiments of this invention are discussed and reference has been made to possible variations within the scope of this invention. These and other variations and modifications in the invention will be apparent to those skilled in the art without departing from the scope of the invention, and it should be understood that this invention is not limited to the illustrative embodiments set forth herein. Accordingly, the invention is to be limited only by the claims provided below and equivalents thereof.
Claims (53)
1. A method of manufacturing a hardenable dental article, the method comprising;
providing a mold cavity in a shape of a hardenable dental article, wherein the mold cavity comprises an opening;
forcing a hardenable dental material into the mold cavity through the opening;
providing a liner between the hardenable dental material and the mold cavity; and
removing the hardenable dental material and the liner from the mold cavity, wherein the hardenable dental material has the shape of the hardenable dental article.
2. A method according to claim 1 , further comprising locating the liner over the opening of the mold cavity, wherein forcing the hardenable dental material into the mold cavity comprises simultaneously forcing the liner into the mold cavity, wherein both the liner and the hardenable dental material take the shape of the hardenable dental article.
3. A method according to claim 1 , further comprising:
locating the liner over the opening of the mold cavity; and
forcing the liner into the mold cavity before forcing the hardenable dental material into the mold cavity.
4. A method according to claim 3 , wherein forcing the liner into the mold cavity comprises only partially replicating the mold cavity with the liner.
5. A method according to claim 4 , wherein forcing the hardenable dental material into the mold cavity further forces the liner into the mold cavity, wherein both the liner and the hardenable dental material take the shape of the hardenable dental article.
6. A method according to claim 3 , wherein forcing the liner into the mold cavity comprises replicating the mold cavity with the liner, wherein the liner takes the shape of the hardenable dental article before forcing the hardenable dental material into the mold cavity.
7. A method according to claim 1 , wherein providing the liner between the hardenable dental material and the mold cavity comprises:
deforming the liner to form a pocket therein; and
locating the hardenable dental material within the pocket in the liner before forcing the hardenable dental material into the mold cavity.
8. A method according to claim 1 , wherein providing the liner between the hardenable dental material and the mold cavity comprises deforming the liner to form a pocket therein by forcing the hardenable dental material into contact with the liner, wherein the hardenable dental material is located within the pocket before forcing the hardenable dental material into the mold cavity.
9. A method according to claim 1 , wherein at least a portion of the liner is retained on the surface of the hardenable dental article after removing the hardenable dental article from the mold cavity.
10. A method according to claim 9 , wherein the liner comprises a film and wherein the method comprises removing the hardenable dental article from the film by deforming the film.
11. A method according to claim 1 , wherein the liner comprises a water soluble polymer.
12. A method according to claim 11 , wherein at least a portion of the liner is retained on the surface of the hardenable dental article after removing the hardenable dental article from the mold cavity, and further wherein the method comprises removing the hardenable dental article from the liner by contacting the liner with water.
13. A method according to claim 1 , wherein the hardenable dental article comprises a hardenable dental crown.
14. A packaged hardenable dental article comprising:
a mass of hardenable dental material in the shape of a hardenable dental article, wherein the hardenable dental article comprises a base and outer surfaces extending from the base;
a package cover conforming to and in intimate contact with the outer surfaces of the hardenable dental article, wherein the package cover comprises a polymeric film plastically deformed by the mass of hardenable dental material; and
a package base facing the base of the hardenable dental article;
wherein the package cover and the package base are attached together about a periphery of the base of the hardenable dental article such that the hardenable dental article is contained within the package base and the package cover.
15. A packaged dental article according to claim 14 , wherein the package cover comprises a sacrificial mold body.
16. A packaged dental article according to claim 14 , wherein the polymeric film comprises a water soluble polymer.
17. A packaged dental article according to claim 14 , wherein the package base comprises a film.
18. A packaged dental article according to claim 14 , wherein the package base and the package cover are attached together by a heat seal bond.
19. A packaged dental article according to claim 14 , wherein the package base and the package cover are adhesively attached together.
20. A packaged dental article according to claim 14 , wherein the hardenable dental article comprises a hardenable dental crown.
21. A dental article comprising:
a sacrificial mold body comprising a sacrificial mold cavity in the shape of a hardenable dental article, wherein the sacrificial mold body comprises at least one line of weakness formed therein, the at least one line of weakness defining at least two mold sections in the sacrificial mold body; and
a mass of hardenable dental material located within the volume of the sacrificial mold cavity such that the hardenable dental material is in the shape of the hardenable dental article.
22. A dental article according to claim 21 , wherein the at least one line of weakness comprises a line of weakness that bisects the sacrificial mold body such that the separation of that line of weakness separates the sacrificial mold body into halves.
23. A dental article according to claim 21 , wherein the at least one line of weakness comprises a plurality of lines of weakness.
24. A dental article according to claim 21 , wherein the at least one line of weakness defines two or more mold sections separated by the lines of weakness.
25. A dental article according to claim 24 , wherein each mold section comprises a flange.
26. A dental article according to claim 21 , wherein the sacrificial mold body comprises a water soluble polymer.
27. A dental article according to claim 21 , wherein the hardenable dental article comprises a hardenable dental crown.
28. A packaged hardenable dental article comprising;
a mass of hardenable dental material in the shape of a hardenable dental article, wherein the hardenable dental article comprises a base and outer surfaces extending from the base;
a package cover conforming to and in intimate contact with the outer surfaces of the hardenable dental article, wherein the package cover comprises a sacrificial mold body comprising a sacrificial mold cavity in the shape of the hardenable dental article, and wherein the sacrificial mold body comprises at least one line of weakness formed therein, the at least one line of weakness defining at least two mold sections in the sacrificial mold body; and
a package base facing the base of the hardenable dental article;
wherein the package cover and the package base are attached together about a periphery of the base of the hardenable dental article such that the hardenable dental article is contained within the package base and the package cover.
29. A packaged hardenable dental article according to claim 28 , wherein the package base is attached to a flange of each of the mold sections.
30. A packaged hardenable dental article according to claim 28 , wherein the package cover comprises a water soluble polymer.
31. A packaged hardenable dental article according to claim 28 , wherein the package base and the package cover are attached together by a heat seal bond.
32. A packaged hardenable dental article according to claim 28 , wherein the package base and the package cover are adhesively attached together.
33. A packaged hardenable dental article according to claim 28 , wherein the at least one line of weakness comprises a plurality of lines of weakness.
34. A packaged hardenable dental article according to claim 28 , wherein each mold section comprises a flange.
35. A packaged hardenable dental article according to claim 28 , wherein the hardenable dental article comprises a hardenable dental crown.
36. A dental article comprising:
a sacrificial mold body comprising a sacrificial mold cavity in a shape of a hardenable dental article, wherein the sacrificial mold cavity conforms to and is in intimate contact with outer surfaces of the hardenable dental article; and
a mass of hardenable dental material located within the volume of the sacrificial mold cavity such that the hardenable dental material is in the shape of the hardenable dental article.
37. A dental article according to claim 36 , wherein the sacrificial mold body comprises a water soluble polymer.
38. A dental article according to claim 36 , wherein the hardenable dental article comprises a hardenable dental crown.
39. A dental article according to claim 36 , wherein the sacrificial mold body comprises an exterior shape that conforms to the shape of the hardenable dental article located within the sacrificial mold cavity.
40. A method of manufacturing a hardenable dental article, the method comprising:
providing a sacrificial mold body comprising a sacrificial mold cavity in a shape of a hardenable dental article, wherein the sacrificial mold body comprises a water soluble polymer; and
forcing a hardenable dental material into the sacrificial mold cavity through the opening, wherein the hardenable dental material takes the shape of the hardenable dental article.
41. A method according to claim 40 , wherein the sacrificial mold body is supported within a support structure when forcing the hardenable dental material into the sacrificial mold cavity.
42. A method according to claim 40 , further comprising removing the hardenable dental article from the sacrificial mold cavity by contacting the sacrificial mold body with water.
43. A method of manufacturing a hardenable dental article, the method comprising:
providing a sacrificial mold body comprising a sacrificial mold cavity in a shape of the hardenable dental article, wherein the sacrificial mold cavity comprises an opening, and wherein the sacrificial mold body comprises at least one line of weakness formed therein, the at least one line of weakness defining at least two mold cavity sections in the sacrificial mold body; and
forcing a hardenable dental material into the sacrificial mold cavity through the opening, wherein the hardenable dental material takes the shape of the hardenable dental article.
44. A method according to claim 43 , further comprising removing the hardenable dental article from the sacrificial mold cavity by separating the sacrificial mold body along the at least one line of weakness.
45. A method according to claim 44 , further comprising a flange on one or more of the mold cavity sections, the flange located proximate the opening into the sacrificial mold cavity, and wherein separating the at least one line of weakness comprises grasping the flange of at least one of the mold cavity sections.
46. A dental article according to claim 21 , wherein the sacrificial mold cavity is in the shape of a crown, and further wherein the sacrificial mold body comprises a base line of weakness defining a base proximate incisal/occlusal surfaces in the sacrificial mold cavity.
47. A dental article according to claim 46 , further comprising a post extending from the base.
48. A dental article according to claim 21 , wherein the sacrifical mold body is formed of one or more materials selected from the group consisting of thermoplastic polymers, thermoplastic elastomers, polyethylenes, polypropylenes, polystyrenes, polyesters, and poly(ethylene terephthalate).
49. A method according to claim 46 , wherein providing the sacrificial mold body comprises molding the sacrificial mold body before forcing the hardenable dental material into the sacrificial mold cavity.
50. A method according to claim 49 , wherein the sacrificial mold cavity is in the shape of a dental crown.
51. A method according to claim 49 , wherein the sacrificial mold body comprises a base line of weakness defining a base proximate incisal/occlusal surfaces in the sacrificial mold cavity.
52. A method according to claim 51 , further comprising a post extending from the base.
53. A method according to claim 49 , wherein the sacrifical mold body is formed of one or more materials selected from the group consisting of thermoplastic polymers, thermoplastic elastomers, polyethylenes, polypropylenes, polystyrenes, polyesters, and poly(ethylene terephthalate).
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US10/643,749 US20050040551A1 (en) | 2003-08-19 | 2003-08-19 | Hardenable dental article and method of manufacturing the same |
PCT/US2004/026634 WO2005018483A2 (en) | 2003-08-19 | 2004-08-17 | Hardenable dental article and method of manufacturing the same |
EP10182767A EP2305165A2 (en) | 2003-08-19 | 2004-08-19 | Hardenable dental article and method of manufacturing the same |
CA002535928A CA2535928A1 (en) | 2003-08-19 | 2004-08-19 | Hardenable dental article and method of manufacturing the same |
US10/921,648 US7811486B2 (en) | 2003-08-19 | 2004-08-19 | Method of manufacturing a hardenable dental article |
CNA2004800238724A CN1838923A (en) | 2003-08-19 | 2004-08-19 | Hardenable dental article and method of manufacturing the same |
JP2006524058A JP4745232B2 (en) | 2003-08-19 | 2004-08-19 | Curable dental article and method for producing the same |
EP10173717A EP2258305A1 (en) | 2003-08-19 | 2004-08-19 | Hardenable dental article and sacrificial mold body |
AT04781639T ATE519448T1 (en) | 2003-08-19 | 2004-08-19 | PRODUCTION METHOD OF A CURED DENTAL ARTICLE AND PACKAGED CURED DENTAL ARTICLES |
PCT/US2004/026991 WO2005018484A2 (en) | 2003-08-19 | 2004-08-19 | Hardenable dental article and method of manufacturing the same |
EP04781639A EP1663053B1 (en) | 2003-08-19 | 2004-08-19 | Method of manufacturing a hardenable dental article and packaged hardenable dental article |
AU2004266716A AU2004266716B2 (en) | 2003-08-19 | 2004-08-19 | Hardenable dental article and method of manufacturing the same |
AU2010200650A AU2010200650B2 (en) | 2003-08-19 | 2010-02-22 | Hardenable dental article and method of manufacturing the same |
JP2010159715A JP2010279708A (en) | 2003-08-19 | 2010-07-14 | Hardenable dental article and method for manufacturing the same |
US12/877,167 US8136657B2 (en) | 2003-08-19 | 2010-09-08 | Packaged hardenable dental article |
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US10/643,749 US20050040551A1 (en) | 2003-08-19 | 2003-08-19 | Hardenable dental article and method of manufacturing the same |
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US12/877,167 Expired - Fee Related US8136657B2 (en) | 2003-08-19 | 2010-09-08 | Packaged hardenable dental article |
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US12/877,167 Expired - Fee Related US8136657B2 (en) | 2003-08-19 | 2010-09-08 | Packaged hardenable dental article |
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EP (3) | EP1663053B1 (en) |
JP (2) | JP4745232B2 (en) |
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Cited By (72)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
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AU2004266716A1 (en) | 2005-03-03 |
JP2010279708A (en) | 2010-12-16 |
EP1663053B1 (en) | 2011-08-10 |
AU2010200650A1 (en) | 2010-03-11 |
US20050100868A1 (en) | 2005-05-12 |
EP2258305A1 (en) | 2010-12-08 |
EP1663053A2 (en) | 2006-06-07 |
ATE519448T1 (en) | 2011-08-15 |
US20100330524A1 (en) | 2010-12-30 |
WO2005018483A2 (en) | 2005-03-03 |
CA2535928A1 (en) | 2005-03-03 |
JP4745232B2 (en) | 2011-08-10 |
AU2010200650B2 (en) | 2012-04-12 |
WO2005018484A2 (en) | 2005-03-03 |
AU2004266716B2 (en) | 2009-11-26 |
WO2005018484A3 (en) | 2005-06-09 |
CN1838923A (en) | 2006-09-27 |
EP2305165A2 (en) | 2011-04-06 |
US8136657B2 (en) | 2012-03-20 |
US7811486B2 (en) | 2010-10-12 |
JP2007502672A (en) | 2007-02-15 |
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